Finish composition for polyolefin fibers



United States Patent FINISH coMPosrrrofi non POLYOLEFIN FIBERS Ann S. Keller, Norristown, and Paul M. Des Coteaux,

West Chester, Pa., assignors, by mesne assignments, to

FMC Corporation, San Jose, Calif., a corporation of Delaware No Drawing. Filed Apr. 19, 1962, Ser. No. 188,866

9 Claims. (Cl. 252-8.75)

This invention relates to finished polyolefin fibers. More particularly, it relates to polyolefin yarns or fibers having applied finishes which enable the yarns to be satisfactorily processed and utilized in the commercial production of textiles and in machine sewing ope-rations.

Polyolefin yarns, for example polypropylene and polyethylene yarns, tend to develop high electrostatic charges and excessive tensions when running over guides, godets and other objects during processing and subsequent handling. The utilization of unfinished polyolefin yarns in textile production and sewing equipment is unsatisfactory.

Static and tension problems have been encountered in the use of other natural and synthetic polymer yarns, and finishes which are satisfactory from both the standpoiuts of application and use have been developed for them. However, the polyolefins have different physical characteristics than most other filament forming polymers and conventional finishes and methods for application thereof are not suitable or effective in providing the necessary fiber to fiber lubrication, proper fiber to metal frictional behavior, and adequate static suppression.

The primary object of this invention is to provide a finished polyolefin yarn which is suitable for high speed processing, textile .and sewing operations.

It is another object of this invention to provide a method of finishing polyolefin fibers which is effective in providing fiber lubrication and static suppression.

These and other objects are accomplished in accordance with this invention with a finish composition for polyolefin fibers comprising (a) From about 90 to 98% by weight of water, and

(b) From about 10 to 2% by weight of a finish consisting essentially of (1) About 1 to 2 parts by weight of a morpholine derivative of the following general formula:

R GET-CH2 ft CHzCfiz wherein R is an alkyl sulfate having 1 to 2 carbon atoms, R is an aliphatic hydrocarbon radical having 12 to 30 carbon atoms and R" is an alkyl radical having 1 to 2 carbon atoms, and

(2) About 2 to 4 parts by weight of a mixture of from 40 to 60% by weight of a C C fatty acid monoester of sorbitan and from 60 to 40% of a poly-oxyethylene modified fatty oil.

This invention also includes polyolefin fibers and yarns, for example, polyethylene, polypropylene and polyisobutylene fibers having incorporated thereon the above described finish. The finish is applied to the fibers and yarns by any known means including bath, spray, padding, control applications or the like.

Generally speaking water base finish compositions are unsatisfactory for application to polyolefin yarn or fibers because of the hydrophobic nature of these polymers. The present finish composition, however, is an exception and provides unexpectedly goo-d lubrication and static suppression.

The morpholine derivatives of this invention include for example, N-cetyl N-ethyl morpholinium ethosulfate; N-cetyl N-methyl morpholinium methosulfate; N-lauryl ice N-ethyl morpholinium ethosulfate; N-stearyl N-ethyl morpholinium ethosulfate; N-soyalyl N-ethyl morpholinium ethosulfate; etc. The monoesters of sorbitan which are useful for this invention include for example, sorbitan monolaurate, sorbitan monopalmitate, sorbitan monostearate, sorbitan monooleate, etc.

The polyoxyethylene modified fatty oils of this invention are obtained by reacting fatty oils with ethylene oxide to obtain polyethylene oxide adducts of a fatty oil. The adducts generally have an ave-rage of from about 50 to 300 or more ethylene oxide units per .glyceride molecule in the fatty oil and preferably from about 150 to 250 ethylene oxide units per molecule. The fatty oils of this invention include for example, castor oil, cotton seed oil, flax seed oil, olive oil, peanut oil, corn oil, coconut oil, soya bean oil, palm oil, perilla oil, tallow, whale oil, bone oil, etc. If desired these oils may be partially hydrogenated to increase saturation and vary the melting range thereof.

In accordance with the present invention allyof the various forms of fibers may be used including continuous monofilament and multifilament, staple, etc. The finish may be scoured after processing, or it may remain on the fiber during further textile ope-rations, as desired.

Many lubricant-antistat combinations were investigated to develop a satisfactory finish composition for polyolefin fiber. Before combinations of lubricants and antistats were tried, however, a screening test was conducted to determine whether the lubricant or antistat material would degrade the polyolefin. Screening involved placing approximately 0.2 ml. of the liquid lubricant or antistat onto a sheet of polypropylene film which had been secured to a glass plate. A piece of graph paper was placed between the film and the glass and served two purposes; it would indicate penetration of the film by the liquid, and also give an indication of the spreading action of the lubricant or antistat. The material passed the screening test if 24 hours of film contact produced no change in film appearance such as waviness or puckering. If puckering did occur it was assumed that it was caused by penetration of the lubricant or antistat into the film and this type of behavior would also occur with a polypropylene fiber. Puckering was considered to be caused by plasticization or 21 similar phenomenon, and test materials causing it were rejected.

The above screening test indicated that parafiinic oils and low molecular weight esters had a noticeable undesirable effect on the test film. Applications of these materials to polyolefin yarn at spinning and the consequential softening or plasticization of this yarn corroborated the screening test results.

. To demonstrate the specificity of this invention there is set forth in the following table a list of finishes, the components of which have passed screening tests but which have been found unsatisfactory either in their application or in their ability to improve characteristics of the yarn.

TAB LE I No. Finish Composition Percent by Weight 1 Diethyl cyclohexylamine salt of lauryl sulfate 3-5 Coconut oil 95-97 2 Diethyl cyclohexylamiue salt of lauryl sulfate 310 Sorbitan monooleate 1. 5-5

Bntyl ste r-rte -95. 5

3 Diethenolamine salt of dilauryl phosphate 3 Sorbitan mouooleate 4 Butyl stearate 93 4 l-hydroxyethyl-Z-oleyl ethyl glyoxolim'um etho- 3 sulfate.

Sorbitan monooleate 3 Bntyl stearate o 94 5 Sorbitan monooleite 5 Butyl stearate 95 TAB LE I-Continued No. Finish Composition Percent by weight 6 1-hydroxyethyl-2-oleyl ethyl glyoxolinium etho- 3 sulfate.

Sorbitan monooleate 4 Coconut oil 93 7 l-hydroxyethyl-2roleyl ethyl glyoxolinium ethosulfate.

Sorbitan trioleate 2O Esterified pentaerythritol 75 8 Diethyl cyclohexylamine salt of lauryl sulfate.

Water 90 9 Diethyl cyclohexylamine salt of lauryl sulfa 10 Diethylene glycol 90 10 Diethyl cyclohexylamine salt of lauryl sulfate 5 Polyethylene glycol (M.W. 400) monooleate 95 ll Diethyl cyclohexylamine salt of lauryl sulfate 5 Dialiphatic ether of polyethylene glycol 95 12 Esterified pentaerythritol 60 Nonionic emul ifying agents 40 13 Finish No. 12 1(] ater 9O 14 Finish No. 12-.. 95

sorbitan monooleate 3 N-cetyl N-ethyl morpholinium ethosulfate 2 15. Finish No. 14 20 Water 80 16..... N-cetyl N-ethyl morpholinium ethosulfate. 5

Technical grade octanol 95 17 N-cetyl N-ethyl morpholinium cthosulfat 10 Water 9O Diethylene glycol 90 19 N-cetyl N -ethyl morpholinium ethosulfate 2 Finish No. 12 98 20".-. Polyoxyethylene modified tallow acid primary 5 amine.

Polyethylene glycol (M.W. 200) monolaurate 95 21 Polyethylene glycol (M.W. 200) monopelargonat 100 22 Polyethylene glycol (M.W. 1000) monostearate- 2 Polyethylene glycol (M.W. 200) monopelargonate 98 23 Diethanolamine salt of dilauryl phosphate 5 Finish No. 22 95 24 Diethanolamine salt of dilauryl phosphate 1O Polyethylene glycol (M.W. 200) monopelargonate 90 25 Polyethylene glycol (M.W. 400) monopalmitate- 2 Water 98 26"--. Diethanolamine salt of dilauryl phosphate- 10 Polyethylene glycol (M.W. 200) monolaurate 90 In addition to the above yarn finish compositions, many other unsatisfactory combinations were tested which were identifiable only under chemical tradenames and/ or broad chemical terms.

Polyolefin fibers and in particular polypropylene fibers are much more difficult to finish than other synthetic or natural polymer fibers. They are non-polar materials and as such have no aflinity for the usual yarn finishes. They are hydrophobic and, in general, water base finish compositions cannot be used to obtain a satisfactory finish. The polyolefin fibers are degraded by treatment with hydrocarbon oil base compositions and become undesirably soft. For these reasons, the finish composition is extremely critical in order to obtain satisfactory yarn characteristics.

The following examples are set forth to demonstrate finish application and composition in accordance with the invention.

Example I A finish was prepared by combining 3 parts of a prepared mixture consisting of 50% by weight of sorbitan monopalmitate and 50% of the polyoxyethylene adduct of castor oil having an average of 200 ethylene oxide units per glyceride molecule in the castor oil, with 1 part of N-cetyl N-ethyl morpholinum ethosulfate. This combination was dispersed in water at a concentration of 5% and applied in this form to polypropylene 800 denier, 34 filament yarn. The finish composition was applied to the polypropylene fibers by means of a kiss roll 6 inches in diameter and 1 /2 inches wide after spinning and just prior to primary take-up. The finished yarn was collected onto a standard pick-up tube with ease. The yarn was also easily stretched through a draw twisting unit with the aid of this finish.

4 Example 11 A similar finish as described in Example I was prepared except that 3 parts of the 50/50 mixture of sorbitan monopalmitate and polyoxyethylene adduct of castor oil were mixed with 2 parts of the morpholine derivative. This combination was mixed with water at a concentraiton of 5% and applied to the polypropylene fiber as described in Example I. Again good results were obtained.

In the processing of this fiber, the finished polypropylene fiber prepared as described in Examples I and II was cut into staple fibers and used in the manufacture of the polypropylene fabric. The finish was found to be an exceptional aid in the textile operation.

Various changes and modifications may be made in practicing the invention without departing from the spirit and scope thereof and, therefore, the invention is not to be limited except as defined in the appended claims.

We claim:

1. A finish composition for polyolefin fibers consisting essentially of (a) from about to 98% by weight of water, and

(b) from about 10 to 2% by weight of a finish consisting essentially of (1) about 1 to 2 parts by weight of a morpholine derivative of the following general formula R OHFOH:

whereinR is an alkyl sulfate having 1 to 2 carbon atoms, R is an aliphatic hydrocarbon radical having 12 to 30 carbon atoms and R" is an alkyl radical having 1 to 2 carbon atoms, and

(2). about 2 to 4 parts by weight of a mixture of from 40 to 60% by weight of a C C fatty acid monoester of sorbitan and from 60 to 40% of a polyoxyethylene modified fatty oil having from about 50 to about 300 ethylene oxide units per glyceride molecule.

2. The finish composition of claim 1 wherein the morpholine derivative is N-cetyl, N-ethyl morpholine ethosulfate.

3. The finish composition of claim 1 wherein the monoester of sorbitan is sorbitan monopalmitate.

4. The finish composition of claim 3 wherein the fatty oil is castor oil.

5. A polyolefin fiber selected from the group consisting of polyethylene, polypropylene and polyisobutylene fibers having incorporated thereon a finish consisting essentially of (a) about 1 to 2 parts by weight of a morphiline derivative of the following general formula wherein R is an alkyl sulfate having 1 to 2 carbon atoms, R is an aliphatic hydrocarbon radical having 12 to 30 carbon atoms and R" is an alkyl radical having 1 to 2 carbon atoms, and

(b) about 2 to 4 parts by weight of a mixture of from 40 to 60% by weight of a C C fatty acid monoester of sorbitan and from 60 to 40% of a polyoxyethylene modified fatty oil having from about 50 to about 300 ethylene oxide units per glyceride molecule.

6. The polyolefin fiber of claim 5, wherein the more pholine derivative is N-cetyl, N-ethylmorpholine ethosulfate. v

7. The polyolefin fiber of claim 5 wherein the monoester of sorbitan is sorbitan monopalmitate. j

6 8. The polyolefin fiber of claim 7 wherein the fatty oil References Cited by the Examiner 1S Castor UNITED STATES PATENTS 9.P1 1 fib h" tdth finish 33535; mcorpora e a 2,668,785 2/1954 Jefierson et al. 252-s.75 XR (a) about 1 to 2 parts by weight of Ncewl, methyl 5 2,695,270 11/1954 1611 15611 et al. 252-8.75 XR morpholinium ethosulfate and 3,009,830 11/1961 Levme 252 s.9 XR (b) 3 parts by weight of a mixture of about 50% by 3048539 8/1962 Kocay et a1 252-89 XR weight of sorbitan monopalmitate and about 50% LEON ROSDOL, Primary Examiner. of a polyoxyethylene modified castor oil having from about 50 to about 300 ethylene oxide units per glycer- 0 JULIUS GREENWALD Exammer' ide molecule. J. T. FEDIGAN, Assistant Examiner. 

1. A FINISH COMPOSITION FOR POLYOLEFIN FIBERS CONSISTING 3 (A) FROM ABOUT 90 TO 98% BY WEIGHT OF WATER, AND ESSENTIALLY OF (B) FROM ABOUT 10 TO 2% BY WEIGHT OF A FINISH CONSISTING ESSENTIALLY OF (1) ABOUT 1 TO 2 PARTS BY WEIGHT OF A MORPHOLINE DERIVATIVE OF THE FOLLOWING GENERAL FORMULA 